Far infrared light quantum flexible sensing fabric and weaving method thereof

Abstract

The application provides a far-infrared light quantum flexible sensing fabric and a weaving method thereof, which comprises a far-infrared light quantum heating area and a flexible sensing area. The heating area is interwoven by warp yarn and weft yarn, the warp yarn comprises an electrode wire and common yarn, and the weft yarn comprises conductive heating yarn and common yarn I. The flexible sensing area is interwoven by warp yarn and weft yarn, the warp yarn of the flexible sensing area is consistent with that of the heating area, and the weft yarn comprises conductive sensing yarn and common yarn II. The flexible sensing area selects yarn with better conductivity and resilience, after pressure action, the conductive yarn is deformed, the conductive yarns in different layers are in contact, the corresponding resistance changes, after the pressure is removed, the sensing area fabric is easier to recover the deformation, the resistance returns to the value before the pressure action, the sensing strain and pressure are obvious, so that the flexible sensing fabric has the advantages of short effective response time, high sensitivity and good response stability.

Description

Technical Field

[0001] This invention relates to the field of flexible sensing fabric technology, and in particular to a far-infrared quantum flexible sensing fabric and its weaving method. Background Technology

[0002] With the increasing intelligence of various products, the demand for sensors is growing. Flexible sensors, as the optimal choice for smart wearable products, have been a key research focus for various research institutions in recent years. Flexible sensors refer to sensors made of flexible materials. Currently, most flexible sensors on the market are thin-film types, often integrated as an add-on into products, especially large-area products like blankets. To ensure monitoring range, the sensor area is generally large, making the integration process complex. Furthermore, thin-film sensors suffer from poor bending resistance and are not washable. Generally, conductive fabric sensors consist of a conductive polymer composite on the outer surface of the fabric, with conductive copper wires connected to both sides to monitor electrical signals. However, they suffer from high contact resistance at the copper wire connections and poor bending resistance. Some conductive fabric sensors, to improve response sensitivity and stability, involve immersion and drying under different fabric elongations to achieve fabric flexibility and stretchability, but this process is complex. Additionally, when blankets or cushions implement heating and intelligent control functions, multiple components are required for separate control, and the heating function can only be turned on and off according to the controller's requirements. Summary of the Invention

[0003] To address the aforementioned issues, this invention provides a far-infrared quantum flexible sensing fabric and its weaving method, integrating far-infrared photothermal heating with the flexible sensing fabric through integrated weaving, achieving an effective combination of function and intelligence. The far-infrared quantum flexible sensing fabric utilizes nano-carbon composite fiber fabric, which is lightweight, soft, and breathable, providing uniform surface heating with a delicate and non-irritating temperature, resulting in a comfortable, non-irritating product feel. Simultaneously, considering the needs of intelligent sensing, the sensing fabric is designed and woven in specific areas, ensuring that the product, in addition to its far-infrared therapeutic heating function, can achieve intelligent control of heating start-up and shutdown, exhibiting high response sensitivity, good response stability, and excellent bending resistance, washability, and durability.

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] A far-infrared quantum flexible sensing fabric includes a far-infrared quantum heating area and a flexible sensing area.

[0006] Preferably, the far-infrared quantum heating area is formed by warp and weft interweaving, and the heating area is formed by warp and weft yarns interweaving, wherein the warp yarns include electrode wires and ordinary yarns, and the weft yarns include conductive heating yarns and ordinary yarn I.

[0007] Furthermore, the electrode yarn in the warp of the far-infrared quantum heating region is at least one of metal-wrapped yarn, metal wire, metal strand, silver-plated yarn, stainless steel yarn, and carbon fiber; at the same time, the ordinary yarn in the warp is at least one of polyester, cotton, Tencel, viscose, linen, polytetrafluoroethylene, and aramid, with a yarn shrinkage rate ≤5% and a yarn heat shrinkage rate ≤4%.

[0008] Furthermore, the conductive heating yarn in the weft yarn of the far-infrared quantum heating region is at least one of nano-carbon composite yarn, carbon fiber, and graphene yarn.

[0009] Furthermore, the resistance of the conductive heating yarn in the weft yarn of the heating zone is 0.1-60KΩ / m.

[0010] Furthermore, the ordinary yarn I in the weft yarn of the heating zone is at least one of polyester, cotton, Tencel, viscose, linen, polytetrafluoroethylene, and aramid.

[0011] Furthermore, the structure of the far-infrared quantum heating region is at least one of plain weave, twill weave, satin weave, double plain weave, small jacquard weave, double layer structure, and triple layer structure.

[0012] Preferably, the far-infrared quantum flexible sensing area is formed by warp and weft interlacing, and the warp yarns of the flexible sensing area are the same as the warp yarns of the heating area, while the weft yarns include conductive sensing yarns and ordinary yarn II.

[0013] Furthermore, the conductive sensing yarn in the weft yarn of the far-infrared quantum flexible sensing region is at least one of conductive composite yarn, stainless steel staple fiber yarn, stainless steel sewing thread, and silver-plated yarn.

[0014] Furthermore, the resistance of the conductive sensing yarn in the weft yarn of the far-infrared quantum flexible sensing region is 30-800Ω / m.

[0015] Furthermore, the ordinary yarn II in the weft yarn of the far-infrared quantum flexible sensing area is at least one of the following: low-elasticity chemical fiber yarn, bulky yarn, and chenille yarn with good resilience, and the fiber elastic recovery rate is ≥94%.

[0016] Furthermore, the ordinary yarn II in the weft yarn is distributed in at least one of the bottom and middle layers of the flexible sensing area.

[0017] Furthermore, the structure of the far-infrared quantum flexible sensing region is at least one of a single-layer structure, a double-layer structure, a triple-layer structure, and a quadruple-layer structure.

[0018] This invention also discloses a method for weaving a far-infrared quantum flexible sensing fabric, comprising the following steps: fixed-length guide tube → yarn hanging → warping → heddle threading → reed cutting → hanging on the machine → weaving → unloading → inspection and finishing → stretching → rolling, to obtain the far-infrared quantum flexible sensing fabric.

[0019] Preferably, the warping process adopts a sliver warping method, where electrode yarns and ordinary yarns are warped separately to ensure the weavability of yarns with different properties.

[0020] Furthermore, the ratio of the number of electrode yarns to ordinary yarns is 5:1 to 20:1.

[0021] Furthermore, the density ratio of the electrode yarn to the ordinary yarn is 1.5:1 to 3:1, and the contact resistance between the electrode yarn and the conductive heating yarn is below 0.2Ω / m.

[0022] Furthermore, the electrode yarns and ordinary yarns are arranged alternately, and their width is determined according to the power and size of the far-infrared quantum flexible sensing fabric.

[0023] Furthermore, the electrode yarn passes through a hanging ring tensioner during warping, and passes through a nylon brush ring when unwinding on the yarn frame, in order to control the uniformity of the unwinding tension of the yarn.

[0024] Beneficial effects of the present invention

[0025] (1) Integrate far-infrared light and heat with flexible sensing fabric to achieve an effective combination of function and intelligence.

[0026] (2) The conductive heating material of the present invention is a nano carbon composite fabric, which is soft and breathable, does not cause sweating when heated, can emit far-infrared rays of 4-16 micrometers, promotes human microcirculation, and the fabric is heated by yarns all over the area, with delicate and uniform temperature, obvious heating and therapeutic effect, the product is light and comfortable, has no foreign body feeling, and is easy to store.

[0027] (3) In line with the needs of intelligent sensing, the flexible sensing area uses yarn with better conductivity and resilience. After pressure is applied, the conductive yarn deforms and different layers of conductive yarn come into contact, resulting in a corresponding change in resistance. After the pressure is removed, the fabric in the sensing area is more likely to recover its deformation and the resistance returns to the value before the pressure was applied. The sensing strain and pressure are obvious, thus making the flexible sensing fabric have a short effective response time, high sensitivity, and good response stability.

[0028] (4) The warp electrode yarn and the ordinary yarn are designed with different density in two zones. The heating area and the flexible sensing area are designed with different fabric structures, so that the flexible sensing fabric woven by the present invention has a more stable structure, is resistant to rubbing, washable and durable.

[0029] (5) Based on the actual needs of the product, a woven sensing fabric can be designed in a specific area. Through the connection of external circuits, the product can achieve intelligent control of starting and stopping heating on the basis of far-infrared physiotherapy heating function, reducing the extra switching actions of users when using the product. Attached Figure Description

[0030] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0031] Figure 1 This is a schematic diagram of the structure of the far-infrared quantum flexible sensing fabric provided in Embodiment 1 of the present invention;

[0032] Figure 2 This is a fabric structure diagram of the far-infrared quantum flexible sensing fabric provided in Embodiment 1 of the present invention.

[0033] Figure 3 This is a schematic diagram of the structure of the far-infrared quantum flexible sensing fabric provided in Embodiment 2 of the present invention;

[0034] Figure 4 This is a fabric structure diagram of the far-infrared quantum flexible sensing fabric provided in Embodiment 2 of the present invention. Detailed Implementation

[0035] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0036] To enable those skilled in the art to better understand the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0037] Example 1

[0038] like Figure 1 and Figure 2 As shown, Figure 1 This is a schematic diagram of the structure of the far-infrared quantum flexible sensing fabric provided in Embodiment 1 of the present invention; Figure 2 This is a fabric structure diagram of the far-infrared quantum flexible sensing fabric provided in Embodiment 1 of the present invention.

[0039] The far-infrared quantum flexible sensing fabric provided by this invention includes a far-infrared quantum heating area 1 and a flexible sensing area 2. The heating area 1 is divided into two parts, namely, upper and lower parts, with the flexible sensing area as the dividing line. The heating area 1 is woven from warp and weft yarns. The warp yarns include metal-wrapped yarn 11 and 300D polyester filaments. The shrinkage rate of the polyester filaments is 4.1%, and the heat shrinkage rate is 3.5%. The weft yarns of the heating area 1 include nano-carbon composite yarn 12. The weave structure of the heating area 1 is plain weave 3.

[0040] The far-infrared quantum flexible sensing area 2 is a single piece, woven from warp and weft threads, with the warp threads of the flexible sensing area 2 being the same as those of the heating area 1. The weft threads of the flexible sensing area 2 are conductive composite threads with a resistance of 130Ω / m, while the ordinary yarn is 300D polyester filament with an elastic recovery rate of 95.2%. Its structure is a double-layer plain weave 4. After the fabric is woven, holes 51 and 52 are punched between the flexible sensing area 2 and the metal yarn 11 to allow for voltage monitoring and resistance changes. The presence of pressure can be determined based on changes in the resistance of the flexible sensing area 2, thereby indicating whether the user is using the product and enabling intelligent control of the functional units of the far-infrared quantum flexible sensing fabric.

[0041] The production process of far-infrared quantum flexible sensing fabric includes the following steps: fixed-length guide tube → yarn hanging → warping → heddle threading → reed cutting → hanging on the machine → weaving → unwinding → inspection and finishing → stretching → winding, to obtain the far-infrared quantum flexible sensing fabric. The warping process must involve the separate warping of metal-wrapped yarn 11 and 300D polyester filament. During warping, the metal-wrapped yarn 11 must pass through a hanging ring tensioner, and when unwinding on the yarn frame, it must pass through a nylon brush ring to ensure uniform warping tension and good warp yarn alignment.

[0042] The functional unit of the far-infrared quantum flexible sensing fabric is 170*72cm, of which the flexible sensing area 2 is located 38.5cm from the top, the width of the flexible sensing area 2 is 6.7cm, and the power of the functional unit is 70W. During warping, the warp yarns are arranged as follows: Yarn A is 300D polyester filament, and yarn B is 11 metal-wrapped yarn; selvage structure: (1A 2A)*5*2, ground structure: (3A 4A 5A 6A)*21 (7B 8B 9B 10B)*6 (3A 4A 5A 6A)*156 (7B 8B 9B 10B)*6 (3A 4A 5A 6A)*5(7B 8B 9B 10B)*6 (3A 4A 5A 6A)*156(7B 8B 9B 10B)*6 (3A 4A 5A 6A)*6 (3A 4A 5A 6A)*21, where the reed number is 52.7#, with 2 strands of A yarn and 3 strands of B yarn, the density ratio of electrode yarn to ordinary yarn is 1:1.5; the ratio of electrode yarn to ordinary yarn count is 1:15.2, and the contact resistance between the electrode yarn and the conductive heating yarn is 0.18Ω / m. During weaving, the weft yarn arrangement is: (50b 22a)*11 (single-layer weft density 52) (64b 8c 64b)*2 (double-layer weft density 104) (50b 22a)*35 (single-layer weft density 52); a is 400D nano-carbon composite yarn, b is 300D polyester filament, and c is 32s / 2 conductive composite yarn. The density unit is: strands / inch.

[0043] Example 2

[0044] like Figure 3 and Figure 4 As shown, Figure 3 This is a schematic diagram of the structure of the far-infrared quantum flexible sensing fabric provided in Embodiment 2 of the present invention; Figure 4 This is a fabric structure diagram of the far-infrared quantum flexible sensing fabric provided in Embodiment 2 of the present invention.

[0045] The far-infrared quantum flexible sensing fabric provided by this invention includes a far-infrared quantum heating region 7 and a flexible sensing region 8. The heating region 7 is divided into three parts, and the flexible sensing region is divided into two parts. The heating region 7 is woven from warp and weft yarns. The warp yarns include metal-wrapped yarn 71 and linen yarn 10s. The shrinkage rate of the linen yarn is 0.5%, and the heat shrinkage rate is 0%. The weft yarns of the heating region 7 include graphene yarn 72. The weave structure of the heating region 7 is plain weave 111.

[0046] The far-infrared quantum flexible sensing area 8 consists of two parts. The flexible sensing area 8 is woven from warp and weft threads, with the warp threads of the flexible sensing area 8 being the same as those of the heating area 7. The weft threads of the flexible sensing area 8 are 10s stainless steel sewing thread with a resistance of 80Ω / m, while the ordinary yarn is 6s chenille yarn with an elastic recovery rate of 97%. Its structure is a single-layer twill weave 112. After the fabric is woven, holes 91, 92, 101, and 102 are punched between the flexible sensing area 8 and the metal yarn 71 to allow for zoned connection and monitoring of voltage changes. The presence of pressure can be determined based on changes in the resistance of the flexible sensing areas 8 and 82. The output signal of the flexible sensing area 8 intelligently controls the functional unit 221 of the far-infrared quantum flexible sensing fabric; the output signal of the flexible sensing area 82 intelligently controls the functional unit 222 of the far-infrared quantum flexible sensing fabric.

[0047] The production process of far-infrared quantum flexible sensing fabric includes the following steps: fixed-length guide tube → yarn hanging → warping → heddle threading → reed cutting → hanging on the machine → weaving → unwinding → inspection and finishing → stretching → winding, to obtain the far-infrared quantum flexible sensing fabric. The warping process must involve split-axis warping of metal-wrapped yarn 71 and linen yarn 10s. During warping, the metal-wrapped yarn 71 must pass through a hanging ring tensioner, and when unwinding on the yarn frame, it must pass through a nylon brush ring to ensure uniform warping tension and good warp yarn alignment.

[0048] The functional unit of the far-infrared quantum flexible sensing fabric is 185*72cm. The flexible sensing area 8 is located 49cm from the top. The width of the flexible sensing areas 8 and 82 is 8cm. The heating area between the flexible sensing areas 8 and 82 is 53cm. The power of the functional unit is 63W. During warping, the warp yarns are arranged as follows: A yarn is 10s linen yarn, B yarn is 11s metal-wrapped yarn; selvage structure: (1A 2A)*10*2, ground structure: (3A 4A 5A 6A)*30 (7B 8B 9B 10B)*6 (3A 4A 5A 6A)*184 (7B 8B 9B 10B)*6 (3A 4A 5A 6A)*7 (7B 8B 9B 10B)*6 (3A 4A 5A 6A)*184 (7B 8B 9B 10B)*6 (3A 4A 5A 6A)*30. A yarn is 2-in, B yarn is 3-in, and the reed is 64.5#. The reed is threaded with 2-in A yarn and 3-in B yarn. The density ratio of electrode yarn to ordinary yarn is 1:1.5; the number of electrode yarns to ordinary yarns is 1:18.5; and the contact resistance between the electrode yarn and the conductive heating yarn is 0.15Ω / m. During weaving, the weft yarn arrangement is: (54b 18a)*17 (6d 2c)*20 (54b 18a)*14 (6d 2c)*20 (55b 18a)*13; a is 300D graphene yarn, b is 300D polyester filament, c is 10s stainless steel sewing thread, and d is 6s chenille yarn. The weft yarn density is 48 yarns / inch.

Claims

1. A far-infrared quantum flexible sensing fabric, characterized in that, The fabric is integrally formed in the same weaving process, including a far-infrared quantum heating area and a flexible sensing area; The heating zone is formed by interlacing warp and weft yarns. The warp yarns include electrode yarns and ordinary yarns, and the weft yarns include conductive heating yarns and ordinary yarn I. The warp yarns of the heating area and the warp yarns of the flexible sensing area are the same set of continuous yarns that run through the entire fabric. The flexible sensing area is formed by interlacing warp and weft yarns, and the weft yarns include conductive sensing yarns and elastic yarns. The conductive sensing yarn is selected from at least one of conductive composite yarn, stainless steel short fiber yarn, stainless steel sewing thread, and silver-plated yarn, and its resistance is 30-130Ω / m. The elastic yarn is selected from at least one of chemical fiber low elasticity yarn, bulky yarn, and chenille yarn, and its fiber elasticity recovery rate is ≥94%; The flexible sensing area has a multi-layer structure, selected from single-layer, double-layer, triple-layer or quadruple-layer structures, and the elastic yarn is arranged in the bottom or middle layer of the sensing area. When the fabric is under pressure, the conductive sensing yarns in the flexible sensing area come into contact with each other or between layers, causing a change in resistance. After the pressure is released, the elastic yarns quickly restore the original shape, realizing an intelligent response for start-stop control.

2. The far-infrared quantum flexible sensing fabric according to claim 1, characterized in that, The electrode yarn in the warp yarn is at least one of metal-wrapped yarn, metal wire, metal strand, silver-plated yarn, stainless steel yarn, and carbon fiber.

3. The far-infrared quantum flexible sensing fabric according to claim 1, characterized in that, The ordinary yarn in the warp yarn is at least one of polyester, cotton, Tencel, viscose, linen, polytetrafluoroethylene, and aramid, with a yarn shrinkage rate of ≤5% and a yarn heat shrinkage rate of ≤4%.

4. The far-infrared quantum flexible sensing fabric according to claim 1, characterized in that, The conductive heating yarn in the weft yarn is at least one of nano-carbon composite yarn, carbon fiber, and graphene yarn.

5. The far-infrared quantum flexible sensing fabric according to claim 1, characterized in that, The resistance of the conductive heating yarn in the weft yarn is 0.1-60KΩ / m.

6. The far-infrared quantum flexible sensing fabric according to claim 1, characterized in that, The ordinary yarn I in the weft yarn is at least one of polyester, cotton, Tencel, viscose, linen, polytetrafluoroethylene, and aramid.

7. The far-infrared quantum flexible sensing fabric according to claim 1, characterized in that, The structure of the heating zone is at least one of plain weave, twill weave, satin weave, double plain weave, small jacquard, double layer weave, and triple layer weave.

8. A method for weaving a far-infrared quantum flexible sensing fabric as described in any one of claims 1-7, characterized in that, The process includes the following steps: fixed-length guide tube → yarn hanging → warping on separate beams → heddle threading → reed cutting → hanging on the machine → weaving → unloading → inspection and finishing → stretching → winding. During the warping process, the warp yarns maintain uniform tension and continuously pass through the heating and sensing areas.

9. The weaving method of the far-infrared quantum flexible sensing fabric according to claim 8, characterized in that, The warping process described above adopts a sliver warping method, where electrode yarns and ordinary yarns are warped separately.

10. The weaving method of the far-infrared quantum flexible sensing fabric according to claim 9, characterized in that, The ratio of electrode yarn to ordinary yarn is 5:1 to 20:

1.

11. The weaving method of the far-infrared quantum flexible sensing fabric according to claim 9, characterized in that, The electrode yarn passes through a hanging ring tensioner during warping and passes through a nylon brush ring when unwinding on the yarn frame.

12. The weaving method of the far-infrared quantum flexible sensing fabric according to claim 9, characterized in that, The density ratio of the electrode yarn to the ordinary yarn is 1.5:1 to 3:1, and the contact resistance between the electrode yarn and the conductive heating yarn is below 0.2Ω / m.

13. The weaving method of the far-infrared quantum flexible sensing fabric according to claim 9, characterized in that, The electrode yarns are arranged alternately with the ordinary yarns, and the number of yarns is designed according to the power and size of the far-infrared quantum flexible sensing fabric.

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